Engineering Support for Refinery

Planning and Scheduling

Improve performance and margins
with aspenONE Engineering
Aspen Product Management
4/9/15

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Agenda
Why Engineering Support for Planning
Engineering Best Practices
Integrated Petroleum Supply Chain Workflow
Key Activities
Why aspenONE Engineering
Next Steps

2010 Aspen Technology, Inc. All rights reserved

Why Engineering Support for Refinery

Planning and Scheduling

Improve and sustain refinery margins

Faster and better feedstock selection
Accurate planning and scheduling models
Agility in response to operational opportunities

Improve Refining Margins

with accurate planning models
through engineering models

2010 Aspen Technology, Inc. All rights reserved

Engineering Best Practices

Feedstock
selection

Capital project
assessments

agility

Plant
operations

decision support for

timely response

Planning
model
updates

for optimal
designs

Performance
Monitoring
of units and
equipment

for accuracy
2010 Aspen Technology, Inc. All rights reserved

Integrating Engineering Business Processes

Enables Best Practices
Asset Engineering Lifecycle and Workflow
Research and
Development

Conceptual
Engineering

Develop
Develop Process
Process
Technology
Technology

Select
Select Process
Process
Technology
Technology

Basic
Engineering

Plant
Operations

Detailed
Engineering

Planning and
Scheduling

Identify
Identify Plant
Plant
Capital
Capital Projects
Projects

Produce
Produce Conceptual
Conceptual
Process
Process Design
Design

Produce
Produce Detailed
Detailed
Process
Process Design
Design

Produce
Produce Conceptual
Conceptual
Engineering
Engineering Design
Design

FEED
FEED

Commission
Commission and
and
Handover
Handover Plant
Plant

Daily
Daily Plant
Plant
Operations
Operations

Produce
Produce Detailed
Detailed
Engineering
Engineering Design
Design

Monitor
Monitor and
and Guide
Guide
Plant
Plant Performance
Performance

Construct
Construct and
and PrePrecommission
commission Plant
Plant

Maintain
Maintain
Equipment
Equipment

Procure
Procure and
and Control
Control Equipment,
Equipment,
Materials
Materials and
and Services
Services

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Select
Select Crude
Crude Oils
Oils
and
and Feedstocks
Feedstocks
Issue
Issue Operating
Operating
Targets
Targets

Planning and Scheduling Model Updates

Challenge

Impact
Challenge

Planners and
process engineers
work in silos
Engineering
models are needed
as input to update
refinery wide
planning models

Reduced predictive
capability and
product quality
Variation between
plan vs. actual

Easier updating of
planning and scheduling
models to reflect actual
plant performance
Solution

Lost Margins

Higher margins
with optimal yields and on-time,
on-spec performance

2010 Aspen Technology, Inc. All rights reserved

Unique to aspenONE
Collaborative workflow to update planning and scheduling models
Business
application

Workflow to

update planning
models using
rigorous models

Support
collaboration

between engineers
and planners

access by planners
and schedulers
through Excel

Ease of use

with calibration
tools and links
between models

2010 Aspen Technology, Inc. All rights reserved

Integrated Petroleum Supply Chain (IPSC)

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Integrated Petroleum Supply Chain (IPSC)

Engineering Models Support

Planning & Scheduling

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Example: A Recent IPSC Project

HQ

Refinery 1

Refinery 2

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Refinery 3

10

Example: A Recent IPSC Project

HQ

Refinery 1

Refinery 2

Refinery 3

Engineering Support for Planning

and Scheduling is built into this project

2010 Aspen Technology, Inc. All rights reserved

11

Refinery Plant Data enters IPSC via the

Engineering Models (see terms next slide)
To IPSC

Simplified Models
to Aspen PIMS &
Scheduler

Aspen RefSYS Flowsheets

Engineering Models for
Planning and Scheduling Support with
Data Reconciliation and Calibration

ASW Link

ASW
On Demand
Manual Data
Collection

AOD
Real Time 24/7
Automatic Data
Collection

RTO
Real Time 24/7 Automatic
Data Collection
APC
DMCplus

Real Time Data Base (IP.21, PI, PHD)

Plant DCS
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12

From IPSC

Plant Targets
(APC setpoints)

Planning and Scheduling Support Workflows

Start with Aspen RefSYS*
Aspen PIMS and
Aspen Petroleum Scheduler

Workflow 1

Assay Tables for

Crude Distillation

LP Submodels
for Reactors

Excel

Excel

Case Study/Excel or
Swing Cut Utility

Case Study/Excel or
PIMS Support Utility

Aspen RefSYS Flowsheets

* The new name for Aspen RefSYS is Aspen HYSYS Petroleum Refining
2010 Aspen Technology, Inc. All rights reserved

14

Workflow 2

Planning and Scheduling Support Workflows

with PIMS to Petroleum Scheduler Integration
Aspen Petroleum
Scheduler
Workflow 3
V7.3 Utilities

Workflow 4

SMC file transfer

Aspen PIMS

Workflow 1

Aspen Petroleum
Scheduler

Aspen PIMS

Assay Tables for

Crude Distillation

LP Submodels
for Reactors

Excel

Excel

Case Study/Excel or
Swing Cut Utility

Case Study/Excel or
PIMS Support Utility

Aspen RefSYS
Flowsheets
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15

Workflow 2

Engineering Support for Planning & Scheduling

Key activities

Crude Assay Distillation Tables

Reactor Submodel Updates

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16

Crude Assay Management

Challenge

Impact
Challenge

Characterizing
each crudes
properties and
composition is time
consuming
Blending crudes
into a single
feedstock
complicates setting
operational targets

Errors can have

significant impact
on simulation
results
Lost opportunity
crude oils

Improved crude oil

blending to increase
accuracy and reduce
simulation times
Solution

Lost Margins

Higher margins
Exploit opportunity feedstocks
and improve operating plans

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17

What is Crude Oil Characterization?

Crude oil characterization converts crude oil lab data into high
fidelity simulation data = Aspen RefSYS Assay
Crude oils are tested in laboratories and lab results are reported.
Lab data is converted into detailed compositions using Aspen
HYSYS/RefSYS pure and hypo components. Bulk lab data is cut
into pure and hypo components which forms an Assay.
Crude Lab Data

Hypos
36-40*
40-50*
---*
200-210*
210-220*
----*
450-460*
460-480*
480-500*
----*
580-600*
600-650*
650-700*
700+*

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18

Why is Crude Oil Characterization Important?

Petroleum refinery profit margins are under great pressure
Crude oil prices and product prices move independently
destabilizing profit margins

Feed and product costs must be well understood to protect

profit margins
Crude oil compositions must be well defined to correctly
price feed stocks and products

2010 Aspen Technology, Inc. All rights reserved

19

How does Crude Oil Characterization

Improve Profits?
Crude oil characterization data is used in three main ways:
Engineering models (Aspen HYSYS Petroleum Refining)
Planning models (Aspen PIMS)
Scheduling models (Aspen Petroleum Scheduler)

Engineering models confirm crude distillation units can

successfully process purchased crude oils
Planning models select optimal crudes oils for refinery
Scheduling models assure smooth and predictable delivery of
products

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20

Where is Crude Oil Characterization Done?

Planning and Scheduling Support tools
Third party products

Flowsheet simulators
Aspen HYSYS Oil Manager
Aspen RefSYS MacroCut
Aspen Plus (ADA)

In house crude cutting programs

Large oil companies

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21

Crude Oil Characterization Methods Used in

Aspen HYSYS and Aspen RefSYS
HYSYS
Oil
Manager

Lab Data:
Gravity,
Distillation,
etc.

RefSYS
Macro Cut
Input
Table
3rd party
assay managers

RefSYS
Assay
Manager

Other crude
cutting programs
RefSYS Macro Cut
Input Table
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22

Feed
Stream
Model

Crude Oil Characterization Usage

Fractionation models re-assemble narrow range hypos
into wider range product cuts for PIMS assay tables

RefSYS cases
confirm crude
unit can
process crude

HYSYS
Oil
Manager

Lab Data:
Gravity,
Distillation,
etc.

RefSYS
Macro Cut
Input
Table

Feed
Stream
Model

HYSYS/RefSYS
Fractionation
Models

Yields
& Properties
for PIMS

3rd party
assay managers
Other crude
cutting programs

RefSYS
Assay
Manager

Yields
& Properties
for Petroleum
Scheduler

RefSYS Macro Cut

Input Table

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